Led replacement kit for high intensity discharge light fixtures

ABSTRACT

Disclosed is a kit for converting an existing high discharge light unit to an LED based light unit, with the option of including a networked capability among a group of LED light units. The kit includes a drop-in component mounting plate on which are mounted an LED light source, sensors including a thermal sensor, a control unit, a DC power supply, a heat sink, and a dimmer unit. A wireless transceiver allows the LED light units to operate as a network, with two way flow of information from the LED light units to a control unit.

PRIORITY/CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No.61/301,130, filed Feb. 10, 2010, the disclosure of which is incorporatedby reference.

TECHNICAL FIELD

The presently disclosed and claimed inventive concept generally relateto an apparatus and method for retrofitting high intensity dischargelights with LED lighting units, and more particularly to a kit foraccomplishing this.

There is a huge installed base of high intensity discharge lights inplaces such as parking lots, outside building illumination, warehouseindoor lighting, freeways and streetlights. The typical technology inthese light units are mercury vapor, metal halide, high pressure sodium,fluorescent, or others. These lights require large amounts ofelectricity, and are not as efficient as newer LED technology. What isneeded is an LED light assembly equivalent to the intensity dischargelamps in light output, but which benefits from the improved efficiencyof LED technology.

SUMMARY OF THE DISCLOSURE

The installed base of high intensity discharge (HID) light fixtures areused in many situations where a large area must be lighted. Thisincludes, but is not limited to, parking lots, parking garages, streetand sidewalk lights, warehouses, and other large buildings. Theinstalled base of high intensity discharge fixtures may include mercuryvapor, metal halide, high pressure sodium, fluorescent or other typesThe disclosed technology is a kit for retrofitting an existing fixtureincorporating a high intensity discharge light bulb so that it operateswith one or more LED light sources. The LED kit may include a driver, bywhich input power is transformed and conditioned to supply power to theLED light sources. The kit also includes one or more LED light sources,with the LED light sources providing 600 lumens or more of light. Atypical kit may reduce a HID light fixture's consumption of electricalpower by more than 50%. The LED light sources may be set at an angle sothat they may be aimed at a selected position. Lenses may be placed overthe LED light sources so that the light from the LEDs is evenlydispersed over an area. These lenses can be customized to suit the lightdispersion or concentration requirements of a particular location.

The retrofit kit may also include a dimmer which can be computer orsensor controlled. The computer controlled dimmer may be controllable bya wireless network from a consol at a security station or a handhelddevice, from which the LED light source's light may be brieflyintensified beyond the normal operating limits in order to better viewan area for security purposes. The dimmer may also be attached tosensors. Sensor inputs to the dimmer may be used to reduce or increasethe light from the LED light sources. A sensor may detect motion, andcould turn the LED light source's light on or intensify the lightwhenever motion is detected. A different sensor may be utilized todetect whether it is daylight or nighttime outside, with the LED lightsources light dimmed during the daytime and intensified at nighttime.Another sensor may detect sound, with the LED light sources light turnedto a higher output when sound is detected that exceeds a minimumthreshold.

A thermal managing system is present so that heat generated from the LEDlight sources does not result in a thermal overload of the LED lightsources. As the thermal maximum threshold of the LED light sources isapproached, the LED light sources would be dimmed so that the maximumthermal operating temperature is not exceeded.

A wireless bidirectional communication network capability may be presentin each kit that allows control and monitoring of the LED light unitfrom a computer or handheld device. Each LED light unit is thus a nodein the network where multiple LED light units comprise a plurality ofnodes interconnected to one another by bidirectional communicationlinks. The bidirectional communication network may include a pluralityof communication loops (horizontal and vertical loops) each comprising aplurality of nodes interconnected to one another by wirelessbidirectional communication links. Each horizontal communication loop isconnected to each vertical communication loop at a node which is commonto both the horizontal communication loop and the vertical communicationloop. This common node (and, in fact, each LED light unit in thenetwork) includes the capability to transfer data packets from thehorizontal communication loop to the vertical communication loop, andvice versa, as a function of destination addresses contained in thepackets.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a diagram showing the connections of the parts of the LEDlighting unit.

FIG. 2 is a diagram showing two directional wireless communicationbetween nodes of the network of LED light units.

FIG. 3 shows a type of light fixture called an acorn fixture.

FIG. 4 shows an acorn fixture with the top removed.

FIG. 5 shows the heat sink and mounting plate of a kit for an acornfixture.

DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS

While the presently disclosed inventive concept(s) is susceptible ofvarious modifications and alternative constructions, certain illustratedembodiments thereof have been shown in the drawings and will bedescribed below in detail. It should be understood, however, that thereis no intention to limit the inventive concept(s) to the specific formdisclosed, but, on the contrary, the presently disclosed and claimedinventive concept(s) is to cover all modifications, alternativeconstructions, and equivalents falling within the spirit and scope ofthe inventive concept(s) as defined in the claims.

FIG. 1 illustrates an embodiment of the inventive concepts, which makeup the kit 10, configured for conversion of high intensity dischargelight units to LED operation. The kit 120 includes an AD to DC powersupply 12 which is connected to line voltage at 24. The DC power isrouted through a dimmer unit 18, which is controlled by a control unit16. Sensor inputs 14 are provide information to control unit 16, whichin turns sends control signals to dimmer unit 18. The thermal sensor 22also sends input to the dimmer unit 18, for varying the output of theLED light source 20. A heat sink 26 is also present. LED light unitrefers to the entire light in the light fixture, and LED light sourcerefers to the light producing LEDs that emit light. The LED lightsources are made of multiple LEDs.

Each of these components can be varied according to a particularinstallation, but a typical installation is to replace an acorn typemetal halide high intensity discharge lamp. The acorn type lightincludes a light fixture, a socket, ballast, and a light bulb, where areremoved or at least disconnected in the case of the ballast, in order toinstall the kit. The fixture and the globe are retained in theretrofitted light unit. The components of the kit are installed on amounting platform 36, and are installed as a unit in the light fixture.The mounting platform 36 is configured to fit in the ballast of theoriginal light and to be thermally connected to the fixture for heatdissipation. For an installation in an acorn type light fixture made foruse with a 175 W bulb, the parts of the kit are installed on themounting plate 36 and that mounting plate 36 is installed in thefixture. Components include an AC to DC power supply driver 12 whichconverts the 277 v AC to 24 v DC. A constant current driver may be used,such as a model LED-INTA_(—)711C-140-F30, made by Philips.

A suitable dimmer unit 18 is exemplified by a model DD032450, made bySimply LEDs. This dimmer unit is capable of reducing the DC current from1050 ma to 300 ma, which modulates the intensity of light emitted by theLED light source 20. Different dimmer parameters would also be suitable,depending on the particular installation.

A thermal sensor 22 is present to detect the buildup of heat from theLED light source 20. Excess heat from the LED decreases the lifespan ofthe LED light source 20. The thermal sensor 22 is thus a protectiondevice for the LED light source 20. When heat exceeding a certainthreshold is sensed, the energy going to the LED light source 20 isreduced by the signal from the thermal sensor 22 to the dimmer unit 18.A suitable thermal sensor is a model QT1206-104F, made by QualityThermistor, but a number of other thermal sensors would be suitable.

Sensor inputs 14 can be a number of different sensors, such as motiondetectors, ambient light detectors, sound detectors, power sensors,light output sensors, and others. These could operate through thecontrol unit 16 and or through the wireless transceiver 28 as a networkof nodes. When acting as non-networked LED light units, designated 30 inthe figures, the motion detector could cause an LED light unit 30 toturn on, or to increase the light intensity. The default light intensitycould be controlled by the ambient light detector, so that LED lightunits 30 are turned off during the day time.

A number of LED light sources are workable in this device, and anexemplary one is a 13 w LED light source containing 12 individual LEDs,made by Bridgelux, model number BXRA-N9802.

FIG. 2 shows the LED light units linked together as a network with eachLED light unit being a node in the network. When the LED light units 30with the kit installed are equipped with a wireless transceiver 28, theymay be linked together to form a network, with the capability ofinteracting with nearby LED light units 30. This mode has the advantageof requiring less signal range from a central control unit, because acontrol signal can be sent from one LED light unit 30 to another, andpassed along to other LED light units 30. This mode of control is shownin FIG. 2, in which a computer or hand held device serves as a centralcontrol unit 32. A control signal 34 can be sent from the control unit32, or can be initiated by any one of the LED light sources 30.

For instance, a motion sensor in one LED light unit 30 can causeadjacent LED light units to activate, or could form a lighted route toan entry point, and activate the entry point lights. The same signalcould be sent to the control unit 32, and the motion activation would berecorded for later review.

Status monitors on the LED light units 30 could send information aboutLED light status, power draw, light output, or other status informationto the control unit 32, by sending a data signal from one LED light unit30 to another, and eventually to the control unit 32.

Some of the LED light units could include a video camera, or could belinked via the network to building mounted video cameras. Thus whenmotion is sensed by an LED light unit, as one example, a nearby LEDlight unit with a video camera or a building mounted video camera couldbe activated.

FIG. 3 shows a type of fixture called an acorn fixture, with a heat sink26 and a globe 40 shown. FIG. 4 shows an acorn fixture with the topremoved, with the power cord, the power supply 12, the control unit 16,the heat sink, the mounting plate 36 and the video camera 42. FIG. 5shows the mounting plate 36, the heat sink 26, and LED light sources 20.

While certain exemplary embodiments are shown in the Figures anddescribed in this disclosure, it is to be distinctly understood that thepresently disclosed inventive concept(s) is not limited thereto but maybe variously embodied to practice within the scope of the followingclaims. From the foregoing description, it will be apparent that variouschanges may be made without departing from the spirit and scope of thedisclosure as defined by the following claims.

1. A kit for retrofitting an existing high intensity discharge lamp in afixture for conversion to an LED light output unit, comprising: amounting plate with heat sink characteristics and configure for thermalcontact with said fixture, said mounting plate serving as a platform forplacement of kit components, with said mounting plate shaped forengagement and attachment with a selected fixture; a driver forsupplying power to one or more LED light sources; one or more LED lightsources; a heat sink separate from said mounting plate; a dimmer unit,for adjusting the power to said one or more LED replacement; a sensorlinked to said dimmer unit, to adjust the power to said one or more LEDlight sources based on a sensed input; and a thermal sensor connected tosaid dimmer unit, for detecting heat overloads and reducing power tosaid one or more LED light sources to keep said replacement LED lightsources within thermal limits.
 2. The kit for retrofitting an existinghigh intensity discharge lamp of claim 1, in which said sensor is amotion detector, configured to signal for brighter light when motion isdetected and for less light or no light when motion is not detected. 3.The kit for retrofitting an existing high intensity discharge lamp ofclaim 2, which further includes a video camera connected to said motionsensor, configured for activation by a signal from said motion detector.4. The kit for retrofitting an existing high intensity discharge lamp ofclaim 1, in which said sensor is a light detector, configured to signalsaid dimmer unit for less or no light when daylight is detected, and forbrighter light when daylight is not detected.
 5. The kit forretrofitting an existing high intensity discharge lamp of claim 1, inwhich said sensor is a sound detector, configured to signal said dimmerunit for brighter light when sound is detected and for less or no lightwhen sound is not detected.
 6. The kit for retrofitting an existing highintensity discharge lamp of claim 1, in which said dimmer unit iscontrollable remotely from a wireless network control computer orhandheld device.
 7. The kit for retrofitting an existing high intensitydischarge lamp of claim 1, in which said dimmer is configured for atemporary boost in power to said one or more LED light sources, ifdirected by a wireless network control computer.
 8. The kit forretrofitting an existing high intensity discharge lamp of claim 1 inwhich said kit includes a bidirectional wireless communication functionfor remote control and monitoring of said one or more LED light units.9. The kit for retrofitting an existing high intensity discharge lamp ofclaim 16 in which said LED light unit is connected to other LED lightunit in a network via said wireless communication unit, with each LEDlight unit forming a node in said network, capable of transferring datato and/or from other LED light units in the network.
 10. The kit forretrofitting an existing high intensity discharge lamp of claim 10 inwhich said information passed between LED light units is a lightintensity instruction.
 11. The kit for retrofitting an existing highintensity discharge lamp of claim 10 in which said information passedbetween LED light units is status information of light fixturecomponents.
 12. The kit for retrofitting an existing high intensitydischarge lamp of claim 10 in which said information passed between LEDlight units is motion sensor information.
 13. The kit for retrofittingan existing high intensity discharge lamp of claim 10 in which saidinformation passed between LED light units is heat and lampidentification number information.
 14. The kit for retrofitting anexisting high intensity discharge lamp of claim 10 in which saidinformation passed between LED light units is video camera data.
 15. Akit for retrofitting an existing high intensity discharge lamp in afixture for conversion to an LED light output unit, comprising: amounting plate with heat sink characteristics and configure for thermalcontact with said fixture, said mounting plate serving as a platform forplacement of kit components, with said mounting plate shaped forengagement and attachment with a selected fixture; a driver forsupplying power to one or more LED light sources; one or more LED lightsources; a heat sink separate from said mounting plate; a dimmer unit,for adjusting the power to said one or more LED replacement; a sensorlinked to said dimmer unit, to adjust the power to said one or more LEDlight sources based on a sensed input; a bidirectional wirelesscommunication unit for remote control and monitoring of said one or moreLED light units; and a thermal sensor connected to said dimmer unit, fordetecting heat overloads and reducing power to said one or more LEDlight sources to keep said replacement LED light sources within thermallimits.
 16. The kit for retrofitting an existing high intensitydischarge lamp of claim 16 in which said LED light unit is connected toother LED light unit in a network via said wireless communication unit,with each LED light unit forming a node in said network, capable oftransferring data to and/or from other LED light units in the network.17. The kit for retrofitting an existing high intensity discharge lampof claim 2, which further includes a video camera connected to saidmotion sensor, configured for activation by a signal from said motiondetector.
 18. The kit for retrofitting an existing high intensitydischarge lamp of claim 10 in which said information passed between LEDlight units is video camera data.
 19. A kit for retrofitting an existinghigh intensity discharge lamp in a fixture for conversion to an LEDlight output unit, comprising: a mounting plate with heat sinkcharacteristics and configure for thermal contact with said fixture,said mounting plate serving as a platform for placement of kitcomponents, with said mounting plate shaped for engagement andattachment with a selected fixture; a driver for supplying power to oneor more LED light sources; one or more LED light sources; a heat sinkseparate from said mounting plate; a dimmer unit, for adjusting thepower to said one or more LED replacement; a sensor linked to saiddimmer unit, to adjust the power to said one or more LED light sourcesbased on a sensed input; a motion sensor for detecting nearby motion andsending a signal to said control unit; a video camera connected to saidmotion sensor, configured for activation by a signal from said motiondetector; a bidirectional wireless communication unit for remote controland monitoring of said one or more LED light units, with said wirelesscommunication unit forming a network of LED lighting units, with eachLED light units being a node in the network for transferring data,including video camera data, from with each LED light unit forming anode in said network; and a thermal sensor connected to said dimmerunit, for detecting heat overloads and reducing power to said one ormore LED light sources to keep said replacement LED light sources withinthermal limits.